GEA WS Energy System Technology-Diesel Engine

Energy System Technology
High Performance Equipment for Diesel Engine Power Plants from

GEA Westfalia Separator
GEA Mechanical Equipment engineering for a better world
2
Your Powerful Partner
Centrifugal separators have been an essential
part of manufacturing since the companys
founding in 1893.
New applications have constantly been added
as a result of the continuous program of
research and development and the know-how
acquired over almost 120 years. Application-
oriented, innovative solu tions in machine
design and process engineering are available
for the mineral oil industry, the dairy,
beverage, food, chemical and pharmaceutical
industries and for biotechnology and pollution
control. The centrifuge was first used for the
purification and dewatering of mineral oil in
1907. Since then, thousands of centrifuges
have been used for the reliable and economic
treatment of fuel and lube oils.
3
The clever way to separate
2 Your Powerful Partner
More quality in power stations
4 Power Station System Solutions
Systems overview for diesel engine power plants
5 High Performance Equipment for Diesel Engine
Power Plants

Centrifugal systems in power stations
6 Process Overview
Self-cleaning separators
7 Double Centripetal Pump
8 GEA Westfalia Separator unitrol
System WMS / SMS in Single Stage
GEA Westfalia Separator minimaXx
10 Manual Cleaning and Self-cleaning Separators

Diesel oil treatment
11 Manual and Self-cleaning Cleaning Solutions

Crude oil treatment
12 Plant Concepts for Treatment
13 Process Overview
Heavy fuel oil treatment
15 Process Overview
Lube oil treatment
17 Process Overview
Sludge treatment
18 System Concepts for the Future
19 Economical Advantages
Ecological Merits

Content
Wastewater treatment
20 Protect the Environment Self-Cleaning
Centrifugal System
22 GEA Westfalia Separator minimaXx

Manual Cleaning Centrifugal System
Fuel oil conditioning system
24 GEA Westfalia Separator ViscoBoosterUnit:
Complete System Between Service Tank
and Engine
Control units
26 Automatic Process
Control More Safety, More Comfort
27 GEA Westfalia Separator minimaXx

Process Control for Every Requirement
Various additional systems and equipment
28 Your Powerful Partner for Complete Systems
Flexible systems
30 Energy Compact Units
Solutions for the Modern Power Plant
Process cooling systems
31 PHE Plate Heat Exchanger
Water desalination system
32 FWG Fresh Water Generator
33 Single Stage Evaporating System
Service that counts
34 Our serv&care Commitment
Proactive Service for Optimum Reliability
in Power Plants
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Power Station System Solutions
More quality in power stations
The power station industry often uses diesel
engines that burn heavy fuel oil, crude oil or
diesel oil. By supplying sepa ration systems
specifically designed for continuous operation
under tough conditions, GEA Westfalia Separator
provides for optimum power output and a
long service life while taking environmental
standards into consideration.
Self-cleaning separators with GEA Westfalia
Separator unitrol systems automatically
monitor the water level in the oil and
the separation of the solid material
round the clock. As a result, optimum
separation efficiency for different fuel and lube
oils is ensured.
Like clockwork
Normally, servicing is necessary after 8,000
to 16,000 operating hours. Additionally,
surveillance-free operation reduces personnel
costs.
The accumulated oil sludge can be processed in
the power station, thereby reduc ing disposal
costs. All separation systems are available as
modules. Other ready-to-connect systems are
also avail able as compact units in combination
with components such as GEA Westfalia
Separator ViscoBoosterUnits (VBU) or Plate
Heat Exchangers (PHE).
Applications
Fuel oil separation
Lube oil separation
Separation of sludge containing
oil and water
Separation of wastewater
System engineering

OTC 2
Energy Compact Unit
for lube oil
GEA Westfalia Separator eagleclass
Smart. Strong. Reliable.
5
High Performance Equipment for
Diesel Engine Power Plants
System overview for diesel engine power plants
GEA Westfalia Separator offers leading
technologies and individual systems for power
station use. System engineering from one source,
high quality of workmanship or unrivalled
worldwide service GEA Westfalia Separator
provides systems to rely on.
Product range overview
Fuel oil treatment
Lube oil treatment
Sludge treatment
Central cooling system
Lube oil cooling system
1
2
3
7
9
13
15
11
12
14
10
4
6
8
5
1
Fuel oil service tank
2
Fuel oil storage tank
3
Fuel oil sludge tank
4
Lube oil sludge tank
5
6
Fuel oil treatment
7
Sludge treatment
8
Lube oil treatment
9
Wastewater tank
10
11
Auxiliaries
12
Charge air cooler M.E.
13
14
HT central coolers
15
LT central coolers
6
Process Overview
The centerpiece of a fuel or lube oil treat ment
system is the centrifugal separator.
Effective treatment ensures that only clean oil
enters the drive unit. The wear on the injection
system and on components such as cylinders,
cylinder liners and the crankshaft of the diesel
engine is minimized.
Suitable types of centrifugal
separators for these duties:
Self-cleaning separators with disc bowl
and automatic bowl ejection facility
Manual cleaning separators with
solid-wall disc bowl
Main duties of centrifugal separators:
Separation of solids
Separation of water
Solids discharge
Untreated
oil feed
Treated
oil discharge
Separated
water discharge
Double centripetal pump Sealing and displacement water
Double Centripetal Pump
Self-cleaning separators with disc bowl and
automatic solids ejection are used where the
percentage of solids in the oil is too high for
manual cleaning. They are used mainly for
the clarification and purification of fuel
oils such as gas oil, diesel oil, crude oil,
heavy fuel oil and lube oil. The separated
solids slide down the underside of the
disc into the solids hold ing space. Self-cleaning
separators eject solid matter automatically while
the separator is running. This avoids shutting
down the separator frequently for cleaning.
The clean oil and the sepa rated water are
conveyed to the discharge under pressure by a
centripetal twin pump.
Self-cleaning separators operate continuously.
Solids ejection occurs either by total or partial
ejections or in a combination. In the case of total
ejection and the combination of total and partial
ejections, there is additional self-clean ing of the
disc stack.
Labor-intensive and costly measures to clean the
discs using CIP (cleaning in place with chemicals)
systems are not necessary. Optimum separation
efficiency over long operating times is ensured.
Major maintenance work is required only after
8,000 to 16,000 operating hours.
Features
Automatic operation
Continuous operating mode
Self-cleaning effect of the bowl
without CIP system
Highly concentrated solids
High separation efficiency
Can be used as clarifier and purifier
Discharge of the light and heavy phase
under pressure by centripetal twin pump
Low noise level
Belt drive
Bowl cross section of a self-cleaning
mineral oil separator with disc bowl
Modern fuel oil and lube oil treatment plants
from GEA Westfalia Separator provide easy
handling and optimum separating efficiency in
difficult situations.
The heart of these systems is a new gene ration
of self-cleaning mineral oil separators with
the GEA Westfalia Separator unitrol system.
These separators operate without regulating
rings and can be used for a wide range of heavy
fuel oils with a specific density up to 1.01 kg / l
as well as for a wide range of lube oils.
The essential features of these separators are the
continuous monitoring of the oil for water and
the continuous monitoring of the solids holding
space for optimum solids filling. Automatic
monitoring means that regulating rings are
unnecessary and operating errors caused
through manual adjustment are eliminated.
The Water Monitoring System (WMS) ensures
reliable water separation. The water in the oil is
separated out and discharged. The Sludge Space
Monitoring System (SMS) checks the solids
space for separated foreign matter.
The oil is displaced prior to a bowl ejection.
The precisely defined displacement volume
minimizes oil losses.
A further innovative feature of these separators
is the bowls new hydraulic system (GEA
Westfalia Separator hydrostop). Extremely short
ejection times combined with maximized solid
ejection ports provide highly concentrated
solids. Further disposal measures are simplified,
disposal costs reduced and environmental
considerations fully taken into account.
During total ejections, preferred by GEA
Westfalia Separator, the disc stack is also cleaned.
Work and cost intensive measures for cleaning
the disc stack by CIP systems are not necessary.
This ensures optimum separating efficiency
over a long period of operation. Maintenance
work is required only after 8,000 to 16,000
operating hours.
Just a few basic models are sufficient to cover
all capacity ranges with the benefit of very
economical spare parts and servicing.
8
GEA Westfalia Separator unitrol System
WMS / SMS in Single Stage
Features
GEA Westfalia Separator unitrol system
in one stage WMS and SMS
Treatment of fuel oils up to 1.01 kg / I
Regulating rings are not required
High separation efficiency even in
critical situations
Automatic adjustment as
clarifier or purifier
Automatic bowl ejection
Continuous processing
Self-cleaning effect of bowl
and disc stack by total ejection
Versatility of application
Safe operation
Belt drive
Low noise level
9
Sealing and displacement water
Untreated
oil feed
Treated oil discharge
Separated
water discharge
Solids discharge
GEA Westfalia Separator unitrol System
Manual Cleaning Separators

10
Bowl cross section of a self-cleaning mineral
oil separator with solid wall disc bowl
Sealing and
displacement water
Solids discharge
Operating water discharge
Untreated
oil feed
Treated oil
discharge
Separated
water discharge
Bowl cross section of a manual
cleaning mineral oil separator with
pressure discharge of the clean oil by
centripetal pump
Sealing water
Separated
water discharge
Untreated
oil feed
Treated
oil discharge
Self-Cleaning Separators
Features
Suitable for both clarifying
and purifying
Solid design
Versatility of application
Low noise level
Features
Automatic operation
Continuous operating mode
Self-cleaning effect of the
bowl without CIP system
High separation efficiency
Can be used as clarifier
and purifier
Closed discharge of the light
phase under pressure by
centripetal pump
Low noise level
Belt drive
Schematic illustration of a
diesel oil treatment system
with manual cleaning
separator without heater
1
3
4
2
5
6
1
Untreated oil feed
2
Strainer
3
Manual cleaning separator
4
Separated water discharge
5
Feed pump
6
Manual Cleaning System
Diesel oil treatment
During transportation from the refinery to the
power plant, diesel oils are often conta minated
with sea water and other impurities. Centrifuges
are essential for the efficient control and removal
of solids and water from fuel oils in fuel oil
treatment systems.
Efficient treatment protects diesel engine
components, such as cylinder liners, pistons,
piston rings and the injection system, from wear.
Cost savings are recouped because of less filter
cleaning, fewer replacements of filter inserts;
and no problem with bacteria growth. The entire
plant concept is completed with the feeder unit.
Self-Cleaning System
Schematic illustration
for oil treatment system
with self-cleaning
separator without heater
2
3
5
4
1
6 7 8
9
10
1 Feed pump
2
Untreated oil feed
3
Untreated oil return
4
Strainer
5
Operating water
6
7

Operating water discharge
8
Solids discharge
9 Self-cleaning separator
10
12
Plant Concepts for Crude Oil Treatment
Increasingly crude oil is used in diesel engine
power plants, especially for crude oil pipeline
projects. The crude oil is delivered to the power
plant in a pre-cleaned and degassed condition.
However, after pre-cleaning the fuel quality is
still too poor to burn in a diesel engine.
The viscosity ranges from diesel oil to heavy fuel
oil. As crude oil contains wax which becomes
liquid only at a temperature of 50C, the separating
temperature is between 60 C and 98 C. Due to
the low flash point, the system must be equipped
with explosion protection.
Centrifuges are essential for the efficient control
and removal of solids and water from fuel oils
in fuel oil safety treatment systems.
Crude oil fuels from different sources must be
purified efficiently. This treatment protects
the diesel engine from wear of important
components such as cylinder liners, pistons,
piston rings and the injection system.
The whole plant concept for crude oil treatment
is rounded off with GEA Westfalia Separator
ViscoBoosterUnits .
Crude oil treatment unit with control panel for use with hazardous material
Process Overview for Crude Oil Treatment
Under normal circumstances, GEA Westfalia
Separator recommends single-stage treatment
for crude oils.
The high efficiency of separation in a single
stage process ensures low wear of the engine.
The high reliability and long service intervals
ensure low operating costs and continuous,
unattended automatic operation for months. The
stand-by centrifuge can be saved for occasional
use in abnormal conditions during increased
solids loading for example.
1
2
3
4
5
6
7
10
11
12 14 15
16
13
8
9
1
Regulating valve
2
Strainer
3
Steam
4
Pre-heater
5
Condensate
6
Steam trap
7
8
Feed pump
9
Strainer
10
Operating water
11
Self-cleaning separator
12
13
Untreated oil feed
14
Purging / flushing
15
Solids discharge
16
Single stage treatment plant
for fuel oil with separator
All equipment with electrical components are
useable for Ex zone 2 (Category 3) Explosion
Group II A or B, Temperature Class T3 in
accordance to ATEX EG-RL94/9. Purging / flushing
for the separator is integrated.
13
14
Plant Concepts for Heavy Fuel Oil Treatment
Owing to its low price, residual oil is widely
available on the international market. During
combustion however, impurities cause corrosion
and deposits. Depending on the application,
treatment systems are available both for high-
grade and low-grade fuels.
When rating the throughput capacity of the
plant, the following fuel oil data are of central
importance:
Viscosity (cSt)
Density (kg/l)
Solids and liquid impurities (%)
The results of a research program confirm
optimum treatment even of fuel oils with
viscosities up to 1650 cSt/50C and densities up
to 1.01kg/l (15C).
Centrifuges are essential for the efficient control
and removal of solids and water from fuel oils
in fuel oil safety treatment systems.
Low-grade fuels from different refining processes
such as atmospheric or vacuum distillation,
as well as from conversion plants such as the
catalytic cracker or visbreaker process, must also
be purified efficiently. This treatment protects the
diesel engine from wear of important components
such as cylinder liners, pistons, piston rings and
the injection system. The whole plant concept
for heavy fuel oil treatment is rounded off with
GEA Westfalia Separator ViscoBoosterUnits .
Energy Compact Unit 2 with two separators type OSD 35 for heavy fuel oil (HFO) treatment
1
2
3 7
10
8
5 6
4 9
11
12 14
15
13
1
Regulating valve
2
Strainer
3
Steam
4
Pre-heater
5
Condensate
6
Steam trap
7
8
Feed Pump
9
Strainer
10
Operating water
11
12
13
Untreated oil feed
14
Solids discharge
15
Single-stage treatment plant for
fuel oil with separator including
GEA Westfalia Separator unitrol system
15
Process Overview for Heavy Fuel Oil Treatment
Under normal circumstances, GEA Westfalia
Separator recommends single-stage treatment for
heavy fuel oils.
The high efficiency of separation in a single-stage
process ensures low wear of the engine. High
reliability and long service intervals ensure low
operating costs and continuous, unattended
automatic operation for months. The stand-
by centrifuge can be saved for occasional use in
abnormal conditions during increased solids
loading for example.
16
Plant Concepts for Lube Oil Treatment
GEA Westfalia Separator lifecyclebenet
During application, lube oils are exposed to
continuous contamination. Foreign matter such
as abrasives, dust, condensate and decomposition
products deposit in the lube oil sump.
Furthermore, acids contained in the oil and
foreign matter from catalysts can lead to
premature aging.
In the case of diesel engines, particularly
trunk piston engines, combustion residue and
unused fuel find their way into the crankcase
compartment, especially with partial load
operation. Sulphurous residues and cleavage
products of the fuel condensate form acid
water with the water vapor produced during
combustion in the cylinder. All this culminates
in damage of bearings, pistons and cylinders.
Centrifugal separation is the most common
method of lube oil treatment. The separator
is located in a by-pass loop within the lube oil
treatment system.
Schematic illustration of a lube oil treatment plant with manual cleaning separator
1
2
3
4
5
1
Feed pump
2
Untreated oil feed
3
Strainer
4
Pre-heater
5
6
7
Treated oil discharge 6
17
Process Overview for Lube Oil Treatment
Self-cleaning mineral oil centrifuges are mainly
used for the purification and dewatering of lube
oils, especially if there is a requirement for
24-hour unattended operation. Lube oil cleaning
reduces wear and prolongs the life of the lube oil.
Schematic illustration
of a lube oil treatment
plant with self-cleaning
separator
1
2
3
4
5
6 13
12
11
9
10
8
7
1
Feed pump
2
Untreated oil feed
3
Strainer
4
Pre-heater
5
Operating water
6
7
Regulating valve
8
Steam
9
Condensate
10
Steam trap
11
12
13
Solids discharge
The whole range of centrifuges is available for
efficient and reliable treatment of lube oil. All
fuel and lube oil treatment centrifuges from
GEA Westfalia Separator have identical design
features allowing the use of common components.
This simplifies management and maintenance.
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1
2
4
5
6
8
7
10
11
9
12
13
14
15
16
17
18
3
1
Regulating valve
2
Steam
3
Pre-heater
4
Condensate
5
Steam trap
6
Feed of oil sludge mixture
7
Feed pump
8
Filter
9
Operating water
10
11
Vibration monitoring
12
13
Sludge concentration unit
14
Oily water
15
Concentrated sludge
16
Sludge transfer unit
17
Centrifugal separator
18
System Concepts for the Future
Sludge Treatment
The trend towards burning higher viscosity
and higher density fuel oils, together with
increasingly common usage of residuals, means
that the amount of sludge being created from
both, fuel and lube oil systems, is increasing.
The sludge is pumped from the sludge tank by
an eccentric screw pump and is fed via a heater
to the centrifugal separator. The sludge
components of water, oil and solids are separated
by centrifugal force. The recovered oil and
water is discharged under pressure by
centripetal pumps.
The concentrated sludge is discharged
intermittently via the sludge transfer unit
into a heated sedimentation tank where final
concentration takes place. Excess water and oil
is allowed to overflow back to the sludge tank.
The concentrated sludge is pumped from the
unit automatically by a solids discharge pump
controlled by a level switch.
A microprocessor-based control cabinet
super vises and controls the complete
concentration process.
0
20
40
60
80
100
120
Feed Oil outlet Water outlet
Solids
Water
Oil
Separation results sludge treatment
Sample taken from
Portion
19
Economical Advantages
Ecological Merits
Approximately 2.5 % of a power plants fuel
consumption remains as an unwanted by-product
in the form of an oily water sludge mixture.
With increasing environmental awareness as
well as strict regulations and controls, most
operators dispose of this sludge by incineration
or by shoreside disposal using contract
companies. In either case sludge disposal is
becoming an expensive problem.
Benefits
Saves up to 90% disposal costs
Recovers valuable fuel oil
Unburdens the wastewater
system from oil residues
Protects our sensitive power ecosystem
GEA Westfalia Separator sludge treatment
plants incorporate a specially designed centrifugal
separator capable of reducing the volume of
sludge for disposal by up to 90%. In addition,
fuel oil is recovered for re-use and recovered
lubricating oil can be used as boiler fuel.
Sludge treatment system ESD 18 with
self-cleaning centrifugal separator to
reduce the disposal costs
20
Wastewater may only be discharged after prior
de-oiling with specially approved treatment
systems. The maximum oil content must not
exceed 15 ppm. The limit has even been reduced
to 10 ppm in some areas.
15 ppm is too much
Oily water may only be discharged if the oil
content in the effluent is below 15 ppm. This
seems small, but GEA Westfalia Separator
believes this is still too high. Moreover, practice
has shown that this value is not attained in many
conventional plants under practical operation
conditions anyway. The further we can reduce
this value, the greater the benefit for our
environment. Wastewater is a mixture of the
following constituents:
Cooling water leakages
Fuel and lube oil leaks
Drainages from settling and sludge tanks
Effluent from various cleaning processes
The product (i.e., oily water without excessive
emulsion) is sucked up from the oily water tank
and fed by the feed pump through the filter and
pre -heater via the feed valve to the separator.
During the start-up or ejection program it is led
back into the oily water tank.
The product flows from above into the center
of the separator bowl. The heavy water phase is
separated from the finest oil particles and then
conveyed under pressure by a centripetal pump
to the discharge.
Protect the Environment
Self-Cleaning Centrifugal System
system WSD 18
21
The separated impurities accumulated in the
sludge space are discharged into the sludge
tank periodically.
The treated water discharge is monitored by an
oil content meter and discharged into the
environment. If the oil content exceeds 15 or
1
Steam
2

Condensate
3

Automatic filter
4

Heater
5

Untreated
wastewater return
6

Pre-de-oiled
wastewater feed
7

Operating water
8

9

Emulsion breaker
10

Solids discharge
11

Recovered waste oil
12

13

Absorption filter
14

Treated wastewater return
15

Treated water discharge
16

Oil monitor
Centrifugal wastewater
treatment with self-
cleaning separator in
combination with
absorption filter and
emulsion breaker
1
2
3
4
5
6
7
8 10
9
11 14
13
16
15
12
10 ppm the water is recirculated into the oily
water tank. If an oil content of 10 ppm is
required, our treatment systems are generally
fitted with an absorption filter that can be
connected to ensure that the required result
is achieved.
22
Manual Cleaning Centrifugal System

The wastewater treatment system will be
supplied as a Compact Unit (CU). The CU
consists of four main components:
minimaXx
separator
Pump / Prefilter
Absorption filter
Control unit
All the components are small and lightweight to
make them easy for transporting and fitting into
the engine room. The components are installed
on a common base frame. The modular concept
can be incorporated into an existing system.
23
1
Pre-de-oiled wastewater feed
2
Pre-filter
3
Waste oil collection tank
4
Treated wastewater return
5
Feed pump
6
7
Treated water discharge
8
Oil monitor
9
Absorption filter
The wastewater treatment system
with the GEA Westfalia Separator
minimaXx
separator type WTC

was specially designed for small
capacities.
The product (i.e., oily water without
excessive emulsion) is fed by the feed
pump into the center of the separator
bowl. Within the rotating bowl, the
product is separated into heavy and
light phases.
The heavy water phase is
separated from the finest oil
droplets and dirt particles and
then conveyed under pressure
by the centripetal pump to the
discharge. If the oil concentration
in the clean water outlet of the
centrifuge exceeds 15 ppm the
water is led through an absorption
filter. The lighter oil phase flows
to the center of the bowl and is
discharged by gravity.
The separated sludge is collected in
the solids holding space and must
be removed by hand.
An intel l igent control and
moni tori ng system assures
problem- free, round- the- clock
unmanned operation. It also
ensures that only water with an
oil content lower than 15 ppm is
released into the environment.
A pre-heater is recommended
if the wastewater contains oils
of a higher viscosity.
24
GEA Westfalia Separator ViscoBoosterUnit:
The Complete System Between Service Tank
and Engine
With ViscoBoosterUnits, GEA Westfalia
Separator offers a complete, compatible system
for safe and economic fuel oil treatment from the
service tank to the engine.
GEA Westfalia Separator ViscoBoosterUnits are
supplied as package systems. They are designed
for 24-hour unattended operation.
Efficient operation of power station diesel
engines requires optimum fuel supply. This key
condition is accomplished by ViscoBoosterUnits
de veloped by GEA Westfalia Separator for fuel
conditioning.
This unit consists of a treatment system that meets
the fuel requirements between the clean oil tank and
injection system for the diesel engine in terms of
the required injection viscosity and temperature.
Supply and booster pumps are provided for stable
system pressure.
The modules are designed for the different en gines
as well as to the required injection viscosity
(approx. 10 24 cSt) and corresponding temperature
(approx. 135 150C).
To be able to ensure a high plant availability
and to achieve the high plant capacities, several
diesel generators are frequently in stalled in
power stations.
We recommend splitting the classical Energy
Unit into a Feeder Unit and, depending on the
number of engines, into several Booster Units.
GEA Westfalia Separator has developed the right
systems for this task.
Benefits
Easy adjustment to the engines in
operation
Higher availability of the complete
insta lla tion
Simple switch-over to HFO / MDO
for each engine
Easy adjustment if the system is
upgraded later
25
VBU (divided module)
Features
Compact, robust design
Good operability
Automatic viscosity control
Automated control system via control
cabinet with redundant power supply
Automatic, compressed-air controlled
filter system for particle separation
Low weight
Easy installation
Low maintenance costs
VBU for power plant
application
1
HFO
2
MDO
3
Feeder pump
4
Strainer
5
Stand-by
6
Pressure control valve
7
Fuel to day tank
8
Fuel from engine
9
Automatic backflushing filter
10
Flow-meter
11
Mixing/Degassing tank
12
Degassing valve
13
Booster pump
14
Stand-by
15
Regulating valve
16
Steam trap
17
Steam or thermal oil
18
Pre-heater
19
Stand-by
20
Condensate or thermal oil
21
Viscosity sensor
22
Fuel to engine
22
21
17
18
19
20
16
14
13
15 12
7
8 3
4
5
2
6
9
1
10
11
26
Keys F1 F4
Soft keypad, screen
dependent
Keys 1 0
Function keypad with
fixed allocation
Status LEDs
Touch display with
backlighting and
4 lines
Easy handling by
Micro Memory Card
which stores setting
and history data for
D10 and E40.
D10 with
text display
Automatic Process Control
More Safety, More Comfort
Control units
The E40 control unit is specically designed for
the GEA Westfalia Separator eagleclass. Even the
most complex separator and system applications
are controlled with precision.
The E40 control unit performs process and
control functions over and above those of the
D10. To facilitate understanding, operating
states, current process values, faults and changes
in system status are shown by a change in
color in the color display. Machine or system-
specific display screens with assigned touch keys
further reduce the possibility of operating faults.
MMC cards function as program memory. The
lifetime data of the systems can be read out by
technical staff for interval or preventive
maintenance purposes.
As an option, the control unit can be patched into
the worldwide web using the Sm@rt Client
server function of the panel and the integrated
Ethernet port. Sm@rt Client allows remote
servicing to be effected quickly and simply. The
machine can be operated and observed from any
workstation within the customers network.
Program control
The control unit controls the program
automatically and monitors the separator.
In addition to all the electrical components on
the separator itself, it is also possible to
incorporate in the control and monitoring system
the peripherals required for a customers
specific application.
1 2
3
5
4
Process Control for Every Requirement

1 Motorstarter box
Motorstarter separator
Motorstarter feed pump
2 OMB 220
Overflow monitoring box
Water seal broken alarm
3 Control unit MC-1
Flow monitoring FAH
4 Control unit CC-1
Flow monitoring FAH
Temperature monitoring TAL / TAH
Preheater interlocking
5 Control unit CD-1
Control and monitoring system
for self-cleaning GEA Westfalia
Separator

minimaXx
separator.
Flow monitoring FAH
Flow monitoring FAL
Clean oil outlet
Temperature monitoring TAL / TAH
Preheater interlocking
Sludge pump control
D10
27
Your Powerful Partner for Complete Systems
Various additional systems and equipment
28
Desalting module for fuel oil washing
Container enclosure for complete modules Fuel oil unloading module
Heat recovery module
29
Additive dosing module Air compressor module
Fuel oil transfer module
Water booster module
ECU 1 ECU 2
The Economical Solution
Energy Compact Units Solutions for
the Modern Power Plant
Flexible systems
GEA Westfalia Separator design engineers have
integrated flexibility into all their products.
Customer benets
All systems:
are installed, piped and electrically wired,
ready for operation on rigid,
stable foundation frames
are completely checked and tested
require small installation costs
are of very compact design, small volume
and weight (less transportation costs)
can be started up immediately
are very easy to operate
Single-, Double- and Multiple-Energy Compact
Units (ECU) are available as standard modules.
30
31
1
2
4
5
6
3
7
8
9
10
11
12
13
14
1
From main engine
2
To main engine
3
Circulation pump
4
From main engine
5
To main engine
6
Circulation pump
7
Auxiliaries
8
Charge air cooler
9
Lube oil cooler
10
Cooling water pump
11
Cooling water
12
LT central cooler
13
HT central cooler
14
Cooling water
PHE Plate Heat Exchanger
Process cooling systems
PHEs are used for cooling purposes, e.g., mainly
for central, lube oil, jacket water circuits, as well
as for auxiliaries, charge air, etc.
A wide range of flexible plate configurations are
offered to cover all heat exchange applications.
Suitable materials like titanium and different
grades of stainless steel, etc. are available.
Features
High heat transmission coefficient
Optimized heat transfer surfaces
Compact design
Low life cycle costs
Simple inspection and maintenance
Low liquid content
Glued and glueless gaskets
FWG Fresh Water Generator
Sea water is fed through the condenser, where it
absorbs the latent heat of the condensing vapor.
Some sea water is used as feed water for the
evaporator while the remaining brine and non-
condensible gases are discharged using a
combined ejector. In the evaporator the sea water
is heated up to the saturation temperature
corresponding to the vacuum maintained by the
ejector, and part of it is evaporated.
The evaporator generally utilizes the waste
heat from the main diesel engine jacket water,
however, other heating media may also be used
(e.g., steam, thermal oil).
The vapor produced passes through the demister
located in the upper casing to remove trapped
droplets of water and is led to the condenser.
The distillate is drawn from the condenser by
the distillate pump and discharged through
the salinity measuring unit. Depending on the
residual salt content of the distillate, it is either
led to the distillate tank or, if the maximum
allowable residual salt content is exceeded, back
to the evaporator.
All parts in contact with sea water are made of
corrosion-resistant materials (CuNi, stainless
steel). The plates are made of titanium.
On request GEA Westfalia Separator can also supply
Multi Flash Water Generators in a range from
100 3000 t/d.
32
Process overview
Sea water Jacket water
Fresh water
Fresh water
Fresh water
generator
Thermal oil / hot water heated
Benefits
Compact
Easy operating, fully automatically
controlled
Reliable
Low weight
Low maintenance costs
Integrated anti-scaling system
Corrosion resistant materials
High performance
1
Heat exchanger
2
Jack water
3
Circulation pump
4
Steam heated
5
Steam
6
Steam jet liquid pump
7
Condensate
8
Sea water
9
Distillate
10
Heating water
11
Jacket water heated
12
Circulation pump
13
Feed water
14
Brine
15
Brine
16
Demister
1
8
9
10
11
12
13
14
15
16
2
3
4
5
6
7
Single Stage Evaporating System
33
34
Our serv&care Commitment
As an EN ISO 9001 company we stand behind the quality of both our products and
our service. Our continuing commitment is to provide customers with the support
they need to maximize productivity and minimize downtime through our serv&care
program. Count on us for round-the-clock assistance in all service areas.
Power pl ant operators not onl y benefi t
from traditional services such as inspection,
maintenance, original spare parts and repair
work provided by the original manufacturer;
they also benefit from pro-active solutions
which avoid risk, e. g. , online and offline
monitoring with GEA Westfalia Separator
wewatch
. These preventive services are the

best guarantee for smooth operation of lube oil
and fuel treatment systems for gas turbines.
Original manufacturers spare parts
We house a large inventory of parts throughout
our 6 North Ameri can offi ce network.
These are ready to be shipped out with a
24-hour turn-around. Only genuine GEA
Westfalia Separator parts are manufactured
under the same strict quality control and
using the same specifications and materials
as our original equipment.
Factory-Authorized Repairs We offer two
full-service repair facilities, one on the West
Coast (Patterson, CA) and one on the East
Coast (Northvale, NJ). This helps to speed up
repair times and keep transportation costs
down. Both facilities are factory-certified and
are staffed with experienced technicians who
have undergone extensive training. If needed,
we offer over 100 rental scrolls or bowl
assemblies to keep customers up and running
while repairs are underway.
35
Field Service We have an extensive field
service team to perform routine and preventive
maintenance and to handle any emergencies
that may come up. Located throughout
North America, these service technicians are
strategically positioned in areas where their
industry and process-specific knowledge is
most valuable. Our service engineers are on
call 24/7.
Training We provide training for your
employees at either your site or one of our
facilities. Our program instructs operators in
the proper handling of the installation, further
ensuring safety.
serv care
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GEA Mechanical Equipment US, Inc.
GEA Westfalia Separator Division
Headquarters:
100 Fairway Court
Northvale, NJ 07647
201-767-3900
Midwest:
725 Tollgate Road, Suite B
Elgin, IL 60123
630-503-4700
South:
4725 Lakeland Commerce Parkway, Suite 4
Lakeland, FL 33805
863-603-8900
Southwest:
2408 Timberloch Place, Suite C-4
The Woodlands, TX 77380
281-465-7900 2
3
7
8
Excellence Passion Integrity Responsibility GEA-versity
GEA Group is a global mechanical engineering company with multi-billion euro sales and operations
in more than 50 countries. Founded in 1881, the company is one of the largest providers of
innovative equipment and process technology. GEA Group is listed in the STOXX Europe 600 Index.
West Coast:
Western Region Customer Support Center
555 Baldwin Road
Patterson, CA 95363
209-895-6300
GEA Mechanical Equipment Canada, Inc.
GEA Westfalia Separator Canada Division
835 Harrington Court
Burlington, ON L7N 3P3
289-288-5500
Toll-Free: 800-722-6622
24-Hour Technical Help: 800-509-9299
www.wsus.com

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Process Control for Every Requirement

. These preventive services are the

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